Angled Terminal Block for Compact Electric Machine Stator
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electrical machines face space constraints that limit their size, leading to reduced performance when high voltage leads need to exit axially and connect to terminal blocks, often requiring additional components for protection and insulation.
Innovation Solution
A stator assembly with a terminal block featuring a non-electrically conductive member that encapsulates an electrically conductive member, allowing for angled connections to maintain a compact form factor without sacrificing performance, and includes seals and flanges for protection against environmental factors and foreign objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the machine size is reduced to meet axial space constraints, then the overall length decreases, but machine performance is reduced
Solution Approach 1:
The terminal block incorporates angled connection zones that allow electrical connections to be made at angles rather than strictly axially. This dimensional change in connection orientation enables compact machine design while maintaining adequate lead length and connection quality, resolving the contradiction between reduced overall length and maintained performance
2Object-affected harmful factors
If additional components (covers, cavities, seals) are added to protect connections, then protection from elements and foreign objects is improved, but device complexity increases
Solution Approach 1:
The terminal block integrates multiple functions into a single component: it provides electrical connections, environmental protection through integrated seals, and structural support. By merging the protective functions into the terminal block itself rather than adding separate covers and cavities, the design achieves protection while reducing overall device complexity
Solution Approach 2:
The terminal block uses a composite structure combining non-conductive material with integrated sealing elements. This composite approach provides both electrical insulation and environmental protection in a single integrated component, reducing the need for additional protective parts
Data Source
AI summary
An electric machine includes a housing having an outer surface and an inner surface that defines an interior portion. The housing also includes a connection zone having a first end portion that extends from the outer surface to a second end portion that is exposed to the interior portion. The connection zone includes a connection passage. A terminal block extends through the connection passage. The terminal block includes a non-electrically conductive member that is sealed against the connection passage, and an electrically conductive member covered by the non-electrically conductive member. The electrically conductive member includes a first end section that extends to a second end section through an intermediate section. The first end section has a first connection zone and the second end section has a second connection zone. The second connection zone is at an angle relative to the first connection zone.